Footwear including a universal cleat assembly

ABSTRACT

An article of footwear including an upper, an outsole defining an opening, a midsole attached to said outsole and defining an opening and a support plate defining a recessed area having a pair of elongated openings, where the support plate is attached to the midsole and the pair of elongated openings are aligned with the openings in the midsole and the outsole. A fastening plate is seated in the support plate and includes non-threaded openings aligned with the elongated openings of the support plate and the openings of the midsole and the outsole. A cleat assembly is removably connected to a designated position on the outsole by inserting threaded ends of a pair of fasteners through the non-threaded openings of the fastening plate, the elongated openings of the support plate, the openings of the midsole and the outsole and into threaded engagement with the cleat assembly.

BACKGROUND

Cycling shoes come in many sizes and shapes and are designed to maintain contact between the bottom of the shoe and the bicycle pedal. The design of the shoe depends on the type and intensity of cycling. Besides maintaining contact with the pedal, cycling shoes are also designed to enhance the power transfer between a cyclist's legs and the pedals.

Conventional cycling shoes are designed to work with clipless pedal systems that temporarily connect the cycling shoe to the pedal using a twist lock configuration similar to ski and snowboard binding systems. These systems employ a cleat attached to the bottom of the cycling shoe and a matching fitting on the pedal. There are two basic types of clipless pedals, road pedals and mountain biking pedals. The mountain biking pedals use a smaller cleat that is recessed within the outsole of the shoe to allow for walking, hiking or running when the user is not on the bicycle. Road pedals use a wider cleat that protrudes from the bottom of the shoe making walking or other activities difficult when the cyclist is not on their bicycle.

Clipless bicycle cleat assemblies typically include a plate that is seated in the outsole of the shoe, a cleat and a spacer. The plate includes one pair or two pairs of threaded holes that align with openings in the outsole. The spacer and the cleat each have corresponding holes that are aligned with one of the pairs of holes in the plate. Fasteners are then inserted through the aligned holes in the spacer and the cleat and are threaded into one of the pairs of threaded holes in the plate to secure the cleat to the bottom of the outsole. After the cleat is secured in the proper location on the bottom of the outsole, the cyclist's shoe is clipped into the fitting on the pedal.

Although the road cycle shoes are difficult to walk in, cyclists still tend to walk on these shoes to get to and from their bike and/or support themselves when stopped. As a result, the pressure of the rider's weight tends to be centered on the cleat which pushes the cleat and cleat fasteners upward into the plate. Over time, this upward pressure wears against the threads of the threaded holes of the plate and eventually strips the holes so that the fasteners can no longer securely fasten the cleat to the shoe.

Accordingly, there is a need for an improved cycling shoe that secures a cleat to a shoe and that is durable to withstand the forces on the cleat resulting from cycling and walking on the shoe.

SUMMARY

The present article of footwear includes a universal, clipless bicycle cleat assembly where a cleat assembly is secured to a designated position on an outsole of a shoe by inserting fasteners from the inside of the shoe into engagement with the cleat assembly to allow for efficient and precise positioning of the cleat assembly relative to a bicycle pedal and for minimizing damage to the cleat assembly during standing, walking or other activity by a user.

In an embodiment, the present article of footwear includes an outsole including an upper surface, a bottom surface and an opening, and a midsole including an upper surface, a bottom surface and an opening, where the upper surface has a recessed area, the bottom surface of the midsole is connected to the upper surface of the outsole and the opening of the midsole is aligned with the opening of the outsole. A support plate defines a recessed area having a pair of elongated openings, where the support plate is configured to fit in the recessed area of the midsole such that the pair of elongated openings are aligned with the openings in the midsole and the outsole. A fastening plate includes a pair of non-threaded openings and is configured to be seated in the recessed area of the support plate, where the non-threaded openings are aligned with the elongated openings of the support plate and the openings of the midsole and the outsole. Also, an upper is attached to the midsole and a cleat assembly is removably connected to a designated position on the outsole by inserting threaded ends of a pair of fasteners through the non-threaded openings of the fastening plate, the elongated openings of the support plate, the openings of the midsole and the outsole and into threaded engagement with the cleat assembly.

In another embodiment, the present article of footwear includes an outsole including an upper surface, a bottom surface and an opening, and a support plate defines a recessed area having a pair of elongated openings, where the support plate is configured to fit in a recessed area of the outsole such that the pair of elongated openings are aligned with the opening in the outsole. A fastening plate includes a first pair of non-threaded openings and a second pair of threaded openings, and is configured to be seated in the recessed area of the support plate, where one of the first pair and second pair of openings is aligned with the elongated openings of the support plate and the opening of the outsole. Also, an upper is attached to the outsole and a cleat assembly is removably connected to a designated position on the outsole by either: inserting threaded ends of a pair of fasteners through the first pair of openings of the fastening plate, the elongated openings of the support plate, the opening of the outsole and into threaded engagement with the cleat assembly, or inserting the threaded ends of the pair of fasteners through the cleat assembly, the opening in the outsole, the elongated openings of the support plate and into threaded engagement with the second pair of openings of the fastening plate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of the present article of footwear.

FIG. 2 is an exploded perspective view of the article of footwear of FIG. 1.

FIG. 3 is a bottom view of the outsole of the article of footwear of shown in FIG. 2.

FIG. 4A is a bottom view of the midsole of the article of footwear shown in FIG. 2.

FIG. 4B is a top view of the midsole of FIG. 4A.

FIG. 5A is a bottom view of the support plate of the article of footwear shown in FIG. 2.

FIG. 5B is a top view of the support plate of FIG. 5A.

FIG. 6A is a top view of the cleat plate of the article of footwear shown in FIG. 2.

FIG. 6B is a bottom view of the support plate of FIG. 6A.

FIG. 7A is a top view of the cleat of the article of footwear shown in FIG. 2.

FIG. 7B is a bottom view of the cleat of FIG. 6A

FIG. 8A is a top view of the spacer of the article of footwear shown in FIG. 2.

FIG. 8B is a bottom view of the spacer of FIG. 8A.

FIG. 9 is another embodiment of the present article of footwear.

DETAILED DESCRIPTION

Referring now to FIGS. 1-8B, the present article of footwear includes a universal, clipless bicycle cleat assembly where the position of the cleat assembly on the article of footwear is adjusted by inserting fasteners from the inside of the shoe into engagement with the cleat assembly to allow for efficient and precise positioning of the cleat assembly relative to a bicycle pedal and for minimizing damage to the cleat assembly during standing, walking or other activity by a user.

The present article of footwear or shoe 20 includes an upper 22 attached to an outsole 24 by stitching, adhesive or glue or other suitable connection method. As shown in FIG. 2, at least parts of a forefoot portion 26 and a heel portion 28 of the outsole 24 include an upper peripheral lip 30. It should be appreciated that the upper lip 30 may extend around part of the periphery of the outsole 24 or about the entire periphery. In the illustrated embodiment, the forefoot and rear portions 26, 28 of the outsole 24 include a durable material, such as Ethylene Vinyl Acetate (EVA), to provide stiffness and rigidity to the shoe 20 for withstanding impact on different terrains and on bicycle pedals. A central gripping portion 32 of the outsole 24 includes a relatively soft gripping material, such as rubber, for enabling the shoe 20 to grip an underlying surface when a user is walking on the shoe or stopped on rough terrain, or to inhibit slipping of the shoe on a pedal. The gripping portion 32 includes inverted diamond-shaped recesses 34 that are configured to assist in gripping a surface of a bicycle pedal and other underlying surfaces such as the ground, rocks and the like. An opposing upper surface 36 of the outsole 24 is generally planar or flat. The outsole 24 further defines a plurality of lateral openings 38 and an opening 40 in the forefoot portion 26 for attaching the present cleat assembly as described below.

A midsole 42 is attached to the upper surface 36 of the outsole 24 using an adhesive or glue, or other suitable attachment method. Alternatively, the midsole 42 and the outsole 24 may be co-molded or press molded as a single integral unit. In the illustrated embodiment, a bottom wall 44 of the midsole 42 includes generally V-shaped lugs 46 that have a size and shape corresponding to the lateral openings 38 defined by the outsole 24. The midsole 42 is preferably made with an EVA or other durable material that will withstand the repeated impact between the lugs 46 and the bottom wall 44, and the ground or underlying surface. As shown in FIGS. 2 and 4B, the midsole 42 includes a base portion 48 including the bottom wall 44 and a peripheral wall 50 that extends upwardly from the bottom wall. The midsole 42, and more specifically, the wall 50 has a size and shape corresponding to an inner surface 52 of the upper lip 30 of the outsole 24 so that the midsole fits within the upper lip for attachment to the upper surface 36 of the outsole. As shown in FIGS. 2, 4A and 4B, a forefoot portion 54 of the midsole 42 defines an opening 56 that aligns with the cleat assembly opening 40 in the outsole 24. An upper surface 58 of the midsole 42 includes a recessed area 60 that extends from the forefoot portion 54 to a heel portion 62 of the midsole.

To enhance the rigidity of the present shoe 20, a support plate 64 is seated in the recessed area 60 of the midsole 42 (see FIGS. 2, 5A and 5B). The support plate 64 has a size and shape that corresponds to the size and shape of the recessed area 60 and may be attached to the midsole 42 using an adhesive, glue or other suitable attachment medium or method. In the illustrated embodiment, the support plate 64 is primarily made with a durable plastic material (forming the body 66 of the support plate) that is co-molded with a metal shank 68. The shank 68 is preferably made of stainless steel to help prevent corrosion and rusting, but may also be made with any other suitable material or combination of materials. Since the shank 68 is co-molded with the body 66, it is not readily removable from the support plate 64. This construction enhances the rigidity and support provided by the shank 68 as part of the support plate 64.

As shown in FIG. 5A, the body 66 of the support plate 64 includes a wall 70 that extends downwardly from a bottom surface 72 of the support plate 64, and has a shape that corresponds to the openings 56 and 40 of the midsole 42 and the outsole 24. As shown in FIG. 5B, an upper surface 78 of the support plate 64 includes a recessed area 80 for receiving a fastening plate 98 as described below. The recessed area 80 includes elongated, oblong openings or through-holes 82 for adjusting the location of the cleat assembly 96 on the shoe 20. A rear portion 84 of the support plate 64 includes several tread or dimpled areas 86 for enhancing the connection between adjacent components of the shoe. As described above, the support plate 64 is preferably made with a solid, durable plastic that provides sufficient support to the cleat assembly 96 as well provide rigidity to the shoe 20. It should be appreciated that the support plate 64 may be made entirely with metal or other suitable materials.

Referring now to FIG. 2, a bottom member 88 is attached to a bottom surface 90 of the upper 22 by stitching or other suitable connection method and includes an opening 92 that corresponds to and aligns with the shank 68 of the support plate 64. An access flap 94 is integrally, hingedly formed with the bottom member 88 to enable a user to pivot or fold back the flap against the bottom member to access the fastening plate 98 from the inside of the shoe 20. Specifically, the access flap 94 moves or pivots between an open position (see FIG. 2) where a user can access the cleat assembly 96 and a closed position where the flap covers the cleat assembly. A bottom surface 97 of the bottom member 88 is attached to at least a portion of the top surface of the midsole 42 by stitching, adhesive or other suitable attachment method for securing the upper 22 to the midsole.

Referring now to FIGS. 2 and 6A-8B, the present cleat assembly 96 includes the fastening plate 98, a cleat or coupler 100, a spacer 102 seated within the coupler and fasteners 104 having threaded ends 105 (FIG. 2) that extend through the fastening plate and are secured to the spacer. The configuration of the present cleat assembly 96 enables the adjustment of the location of the cleat assembly from inside of the shoe 20 thereby allowing the user to adjust the position of the cleat assembly while the cleat assembly is attached to a bicycle pedal to ensure the proper positioning of the shoe on the pedal. The cleat assembly 96 is also designed to reduce damage to the cleat assembly when the user is standing, walking or running on the shoe.

As shown in FIGS. 6A and 6B, the fastening plate 98 has a generally rectangular configuration with opposing indents 106. The indents 106 have a size and shape that correspond to protrusions 108 (FIG. 5B) formed in the support plate 64 that extend into the recessed area 80 of the shank 68. When the fastening plate 98 is inserted into the recessed area 80, the protrusions 108 align with and extend into the indents 106 to guide the proper insertion of the fastening plate 98 into the recessed area 80 and also minimize movement of the fastening plate within that recessed area. In an embodiment, the fastening plate 98 is made of stainless steel to provide strength, rigidity and durability to the shoe 20 and also to reduce rust and corrosion over time. It should be appreciated that the fastening plate 98 may be made of any suitable metal, such as aluminum, or other suitable materials or combination of materials.

In the illustrated embodiment, the fastening plate 106 includes two pairs of openings or through-holes. A first pair of openings 110 includes threads for allowing fasteners of conventional cleat assemblies to be inserted through the cleat from outside of the shoe and secured to the fastening plate. The second pair of openings 112 does not include threads and allows the fasteners 104 to be inserted through the openings and seated in the fastening plate 98 such that an upper surface 114 of each fastener fits in recessed portions 115 of the openings and is flush with an upper or top surface 116 of the fastening plate. The fastening plate 98 may be rotated to align the first pair of openings 110 or the second pair of openings 112 with the openings 82 in the shank 68 for adjusting the positioning of the cleat assembly 96 relative to the outsole 24 depending on whether the present cleat assembly or a conventional cleat assembly is being used on the shoe. Additionally, to minimize debris and moisture entering the shoe 20, a seal member, such as a rubber gasket 118, having a size and shape corresponding to the size and shape of the fastening plate 98 is inserted between the fastening plate and the shank 68. The rubber gasket 118 includes a pair of openings 120 that are aligned with the first or second pair of openings 110, 112 of the fastening plate 98 depending on which of the openings are being used by a user.

The cleat or coupler 100 includes an oblong opening 122 that has a size and shape to correspond with both the first or second pair of openings 110, 112 of the fastening plate 98. As shown in FIGS. 2, 7A and 7B, the opening 122 in the cleat 100 is aligned with the elongated openings 82 in the shank 68 so that the fasteners 104 may be inserted through the fastening plate 98, the shank 68 and the outsole 24 and the cleat 100. The cleat 100 includes an upper surface 124 and a bottom surface 126. The upper surface 124 includes a plurality of teeth 128 (see FIG. 7B) that engage and grip the bottom surface 72 of the support plate 64, and more specifically, the shank 68, for holding the cleat 100 in position on the outsole 24. The opposing or bottom surface 126 of the cleat 100 defines an oval recessed area 130 for receiving the spacer 102. It should be appreciated that the cleat 100 is preferably made of stainless steel but may be made of any suitable material or combination of materials.

Referring to FIGS. 8A and 8B, the spacer 102 includes a pair of threaded holes or openings 132 that are aligned with the openings 122 in the cleat 100 and the shank 68. The spacer 102 has a size and shape that corresponds to the size and shape of the recessed area 130 in the cleat 100 such that the spacer is seated in the recessed area and receives the threaded ends of the fasteners 104 for securing the cleat to a bottom surface 134 (FIG. 3) of the outsole 24. The spacer 102 is preferably made of stainless steel but may be made of any suitable material or combination of materials. It should also be appreciated that the spacer 102 and the recessed area 130 of the cleat 100 may be any suitable size and shape.

A footbed 136 having a designated thickness based on desired cushioning and comfort levels for a user is inserted into the shoe 20 and placed over the bottom member 88 to provide support and comfort to a user's foot. The footbed 136 is removable from the interior of the shoe 20 so that a user can access the cleat assembly 96 as described above. It should be appreciated that the footbed 136 may be made out of EVA or any suitable material.

In the illustrated embodiment, the present cleat assembly 96 is attached to the shoe 20 by moving the access flap 94 of the bottom member 88 from the closed position to the open position (FIG. 2) and inserting the fastening plate 98 into the recessed area 80 of the support plate 64. A user then reaches inside the shoe 20 and inserts the fasteners 104 through the non-threaded, second pair of openings 112 of the fastening plate 98 until the heads of the fasteners 104 are seated within the recessed portions 115 of the openings 112. The threaded ends 105 of the fasteners 104 extend through the openings 112 in the fastening plate 98, the openings 82 in the support plate 64 (i.e., the shank 68), and the openings 122 in the cleat 100 and are threaded with or connected to the threaded openings 132 of the spacer 102. Once the location of the cleat 100 is set on the outsole 24, the user uses a tool such as a cleat tightener 138 (FIG. 1) or a screwdriver, which has an end that mates with a shaped recess 140 formed in the heads of the fasteners 104, to tighten the fasteners. The user rotates the tool 138 and thereby the fasteners 104 in a clockwise direction, which causes the threaded ends 105 of the fasteners to threadingly engage the openings 132 of the spacer 102 and tighten the cleat 100 against the bottom surface 134 of the outsole 24. When the cleat 100 is secured in the desired position on the outsole 24, the tool 138 is removed from the fastener head and the access flap 94 is moved to the closed position to cover the cleat assembly 96. The footbed 136 is re-inserted in the shoe 20 and the user may now insert their foot into the shoe for use during riding, standing, walking, running or other activity. The above operations are reversed if the user wants to move the location of the cleat assembly 96 (i.e., the cleat 100) relative to the pedal or remove the cleat assembly from the shoe 20 for repair or replacement.

As shown in FIG. 1, a front portion 142 of the upper 22 includes a tool opening 144 for allowing access to the fasteners 100 by the tool 138. The tool opening 144 in the upper 22 makes it easier for a user to insert the tool 138 in the shaped recesses 140 of the fastener heads for tightening the cleat assembly 96 to the outsole 24 since space inside the shoe 20 is limited. A cover 146 is movably connected to the upper 22 and moves between an open position (see FIG. 1), which allows access to the tool opening, and a closed position, which covers the tool opening 144 to inhibit water and other substances from entering the interior of the shoe 20. In an embodiment, a suitable connector (not shown), such as a hook and loop fastener or snap connector, is placed on the cover 146 and near the tool opening 144 to temporarily, securely hold the cover against the upper 22 for closing and sealing the tool opening. It should be appreciated that the tool opening 144 may be any suitable size or shape and may be in any suitable location on the upper 22.

As discussed above, the first pair of openings 110 of the fastening plate 98 includes threads such that a conventional cleat assembly may be used on the shoe 20. With conventional cleat assemblies, the fasteners 104 are inserted from outside of the shoe 20 and through the cleat 100 and into the threaded openings 110 on the fastening plate 98. Thus, the fastening plate 98 allows for both conventional cleat assemblies and cleat assemblies defined by the present invention to be secured to the outsole 24 of the shoe 20. This provides greater flexibility and enables users to only need one pair of cycling shoes as opposed to different pairs of cycling shoes having different cleat assemblies.

Referring now to FIG. 9, in another embodiment of the present article of footwear, the wall 70 surrounding the shank 68 includes two support ears 200 located on opposing sides of the shank. The support ears 200 of the cleat attachment area 76 of the outsole 24 extend outwardly towards the sides of the shoe 20. Because conventional bicycle shoe outsoles are typically made entirely of EVA or another relatively hard material, the cleat assembly attachment areas on the conventional outsoles vary based on tolerances. Thus, such attachment areas are inconsistent amongst different cycling shoes thereby varying the ease with which the cleat assemblies are attached to a pedal. In the present embodiment, the shoe 20, and more particularly, the support ears 200 in the cleat attachment area 76 of the shoe expand the size of the attachment area to account for such variances and material tolerances such that the present shoe 20 can be consistently and easily connected to a bicycle pedal. It should be appreciated that the support ears 200 may be any suitable size or shape and may extend to the sides of the shoe 20 or to any portion therebetween.

While a particular embodiment of the present article of footwear has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects. 

What is claimed is:
 1. An article of footwear comprising: an outsole including an upper surface and a bottom surface and defining an opening; a midsole including an upper surface and a bottom surface and defining an opening, said upper surface having a recessed area, wherein said bottom surface of the midsole is connected to said upper surface of said outsole and said opening of said midsole is aligned with said opening of said outsole; a support plate defining a recessed area having a pair of elongated openings, said support plate being configured to fit in said recessed area of said midsole such that said pair of elongated openings are aligned with said openings in said midsole and said outsole; a fastening plate including a pair of non-threaded openings and configured to be seated in said recessed area of said support plate, said non-threaded openings being aligned with said elongated openings of said support plate and said openings of said midsole and said outsole; an upper attached to said midsole; and a cleat assembly removably connected to a designated position on said outsole by inserting threaded ends of a pair of fasteners through said non-threaded openings of said fastening plate, said elongated openings of said support plate, said openings of said midsole and said outsole and into threaded engagement with said cleat assembly.
 2. The article of footwear of claim 1, wherein said cleat assembly includes a removable spacer having a pair of threaded openings, and wherein said threaded ends of said fasteners threadingly engage said threaded openings of said spacer to secure said cleat assembly to said outsole.
 3. The article of footwear of claim 1, wherein said support plate includes a pair of opposing support ears, said openings in said midsole and said outsole being configured to have a size and shape to receive said support ears.
 4. The article of footwear of claim 1, further comprising a rubber gasket positioned between said fastening plate and said support plate, wherein said rubber gasket includes a pair of openings aligned with said non-threaded openings of said fastening plate.
 5. The article of footwear of claim 1, further comprising a footbed configured to be inserted within and removably connected to said upper.
 6. The article of footwear of claim 1, further comprising a bottom member attached to said upper, said bottom member defining an access opening aligned with said fastening plate seated in said support plate for allowing access to said fastening plate.
 7. The article of footwear of claim 6, wherein said bottom member includes an access flap hingedly connected to said bottom member, said access flap being movable between an open position away from said access opening and a closed position covering said access opening.
 8. The article of footwear of claim 1, wherein said upper includes a tool opening for receiving a tool configured to rotate said fasteners.
 9. The article of footwear of claim 8, wherein said upper includes a cover hingedly connected to said upper, said cover being movable between an open position away from said upper and a closed position covering said tool opening.
 10. The article of footwear of claim 1, wherein said outsole includes a plurality of lateral openings and said midsole includes a bottom surface and a plurality of lugs extending downwardly from said bottom surface and configured to extend through said lateral openings.
 11. The article of footwear of claim 1, wherein said cleat assembly includes a cleat defining a recess and a removable spacer seated in said recess, said spacer including a pair of threaded openings, wherein said threaded ends of said fasteners threadingly engage said openings of said spacer to secure said cleat assembly to said outsole.
 12. An article of footwear comprising: an outsole including an upper surface and a bottom surface and defining an opening, said upper surface defining a recessed area; a support plate defining a recessed area having a pair of elongated openings, said support plate being configured to fit in said recessed area of said outsole such that said pair of elongated openings are aligned with said opening in said outsole; a fastening plate including a first pair of non-threaded openings and a second pair of threaded openings, said fastening plate being configured to be seated in said recessed area of said support plate, one of said first pair and second pair of openings being aligned with said elongated openings of said support plate and said opening of said outsole; an upper attached to said outsole; and a cleat assembly removably connected to a designated position on said outsole by either: inserting threaded ends of a pair of fasteners through said first pair of openings of said fastening plate, said elongated openings of said support plate, said opening of said outsole and into threaded engagement with said cleat assembly; or inserting said threaded ends of said pair of fasteners through said cleat assembly, said opening in said outsole, said elongated openings of said support plate and into threaded engagement with said second pair of openings of said fastening plate.
 13. The article of footwear of claim 12, wherein said support plate includes a pair of opposing support ears, said opening in said outsole being configured to have a size and shape to receive said support ears.
 14. The article of footwear of claim 12, further comprising a rubber gasket positioned between said fastening plate and said support plate, wherein said rubber gasket includes a pair of openings aligned with said non-threaded openings of said fastening plate.
 15. The article of footwear of claim 12, further comprising a footbed configured to be inserted within and removably connected to said upper.
 16. The article of footwear of claim 12, further comprising a bottom member attached to said upper, said bottom member defining an access opening aligned with said fastening plate seated in said support plate for allowing access to said fastening plate.
 17. The article of footwear of claim 16, wherein said bottom member includes an access flap hingedly connected to said bottom member, said access flap being movable between an open position away from said access opening and a closed position covering said access opening.
 18. The article of footwear of claim 12, wherein said upper includes a tool opening for receiving a tool configured to rotate said fasteners.
 19. The article of footwear of claim 18, wherein said upper includes a cover hingedly connected to said upper, said cover being movable between an open position away from said upper and a closed position covering said tool opening.
 20. The article of footwear of claim 12, wherein said outsole includes a plurality of lateral openings and said midsole includes a bottom surface and a plurality of lugs extending downwardly from said bottom surface and configured to extend through said lateral openings. 